Hyundai Kona Common Problems

The Hyundai Kona is a small SUV sold here since late 2017. The first generation (OS, 2017 to 2023) came with a 2.0-litre Nu MPi petrol engine and front-wheel drive, using a six-speed automatic until the 2021 facelift and a CVT after it, or a 1.6-litre T-GDi turbo with a seven-speed dry dual-clutch and all-wheel drive. The Kona Electric joined the range early in this generation, and the Kona N, with a 2.0-litre turbo and an eight-speed wet dual-clutch, followed in 2021. The second generation (SX2, from 2023) offers a 2.0 with a CVT, a 1.6 turbo with an eight-speed automatic, a 1.6 hybrid with a six-speed dual-clutch, and a new Electric. Reliability is generally sound, but early 2.0 engines, the turbo's dual-clutch and the first Electric batteries all have a history.

Piston ring failure and engine knock (2.0 Nu MPi, 2018 to 2020)

Some first-generation Kona 2.0 engines were built with piston rings that did not meet specification. The rings and cylinder bores can be damaged, and the first signs are a knocking noise from the engine, oil use between services and, in the worst cases, stalling or an oil leak.

Hyundai Australia recalled 2018 to 2020 Kona and Veloster models for this and said some engines here had already been replaced. A matching US campaign traced it to oil rings with inconsistent heat treatment. The remedy is a dealer inspection and a new engine if damage is found, free under the recall. Outside a recall, a replacement engine fitted at your cost would likely run to roughly $6,000 to $10,000, so a knocking 2.0 with no recall record is one to walk away from. A class action has also been filed in the Federal Court alleging defects in the 2018 to 2020 Kona 2.0 and 1.6 turbo engines and the Kona N engine; check its current status.

Dual-clutch judder and hesitation (1.6 T-GDi, seven-speed DCT, 2017 to 2023)

The turbo Kona uses a seven-speed dry dual-clutch gearbox. Some owners report shudder when creeping in traffic, a delay when pulling away from a stop, and lurching while parking. Dry clutches dislike heat and slipping at walking pace, so cars that live in stop-start traffic suffer most.

Hyundai issued an overseas service bulletin for 2018 to 2021 turbo Konas with revised anti-judder software for the transmission control unit, and clutch replacement where software is not enough. Ask a Hyundai dealer whether the update applies to the car. A new clutch pack outside warranty is a bigger bill, roughly $2,500 to $4,500. The 2021 facelift kept this gearbox. The second-generation 1.6 turbo uses an eight-speed torque-converter automatic instead.

High-voltage battery cell defects (Kona Electric, 2018 to 2020 builds)

Early Kona Electrics used LG battery cells made between late 2017 and March 2020, some with an internal defect that could cause a short circuit and fire after charging. Hyundai first issued a battery management software update and told owners to avoid overnight charging at home, then replaced the battery packs on affected Australian cars from 2021. Hyundai said in 2021 that there had been no battery fires in Australia.

A later battery software campaign is reported to cover most OS Kona Electrics, including cars that already have a new pack. Most need only a software update, and some need a cell repair. The battery carries an eight-year, 160,000 km warranty from new, so check how much is left.

Drive unit clicking and grinding noise (Kona Electric, 2019 to 2021)

Some Kona Electric owners, mostly on overseas forums, report a clicking, tapping or grinding noise from the front drive unit when coasting at low speed or under regenerative braking. Owner theories point to wear in the splines between the motor and the reduction gear, but the cause is not confirmed. Owners report dealers replacing reduction gears and in some cases the motor, with mixed results. Check what warranty cover is left, as a fix at your cost can run into thousands of dollars.

Loss of drive and fuel pump faults (Kona N, 2.0 T-GDi, 2021 to 2023)

The Kona N's eight-speed wet dual-clutch was part of a wider Hyundai campaign: the gearbox software did not handle certain transmission oil pump faults correctly, which could cause reduced acceleration and then a loss of power. The fix is a software update. A later campaign covers the high-pressure fuel pump, where a manufacturing defect in the fuel control valve can let in excess fuel and stall the engine. Dealers inspect the pump and replace it if needed. Both are free. Kona Ns are often driven hard, so look closely at tyres, brakes and oil change records too.

Recalls and safety

Recall themes for the first-generation Kona include the 2.0 piston rings, the Electric battery and battery software, braking software on early Electrics, and a 2018 campaign on 1.6 turbos where a front brake line could touch the exhaust. Kona N campaigns cover the dual-clutch software and the fuel pump. On the second generation there are campaigns for wiring near the engine control unit on 2023 1.6 turbos (a fire risk in a crash), an EGR valve sensor on 2024 2.0 cars that can cut power, and instrument cluster software on 2025 cars. Have a Hyundai dealer check the VIN for open recalls, and see our recalls page.

Buying a used Hyundai Kona? What to check

• Cold start: Start a 2.0 from cold and listen for knocking or ticking that does not fade. Ask whether the piston ring inspection or an engine replacement was done.
• Oil level: Pull the dipstick. A low reading only a few thousand kilometres after a service points to oil use on either petrol engine.
• Dual-clutch behaviour: In a turbo or N, creep in traffic, reverse up a slope and pull away gently. Judder, slip or a clunk means clutch wear or missing software updates.
• Battery paperwork: On an Electric, ask for proof of the battery replacement or software work, and have a dealer read the battery state of health.
• Drive unit noise: Coast an Electric at low speed with the windows down and listen for clicking or grinding as regen comes in.
• Charging: Test the Electric on both a home charger and a DC fast charger if you can, and watch for warning messages.
• Kona N history: Look for track use, heavy tyre and brake wear, and oil changes at or inside the scheduled intervals.
• Service record: Check every 12-month service was done on time (turbo models have a shorter kilometre limit than the 2.0) and how much of the five-year warranty is left.

Before you buy, run a VIN check on the car and work through our Hyundai Kona buying checklist.

The verdict

For most buyers the pick is a 2021 to 2023 facelifted Kona 2.0 with the CVT, or a later 2.0, with a full service record. A 2018 to 2020 2.0 is fine if the piston ring recall work is documented and the engine runs quietly. Choose the 1.6 turbo only if most of your driving is on open roads, and test the dual-clutch hard. Early Kona Electrics are sound buys once the battery replacement and software updates are proven. The second generation is too new for a clear fault pattern beyond its recalls.